Container having fixable cover

ABSTRACT

A container includes a container body which defines a volume wherein a product is to be held and a cover that engages the container body to provide sufficient sealing in conjunction with the container body for the product contained therein. The container body defines an opening to the volume and the opening defines a throat of the container. The cover is configured to act as a plug in the throat of the container which provides an interference fit. The cover has an outer flange which defines tabs and the container body has an outer flange which defines notches which are configured to mechanically interlock with the tabs when the tabs are bent to engage the notches and thereby secure the cover to the container.

BACKGROUND

The present invention provides a container that includes a cup, or cup-like voluminous vessel, and a cover that engages an opening of the cup with an interference fit sufficient for sealing a product contained in the cup. The cover is provided with a flange having tabs that interlock with notches in a flange of the cup thereby insuring that the cover is not dislodged from the cup during transport and handling. Preferably, but optionally, the cup and cover are formed of sustainable raw fiber materials as molded fiber manufactured products that are biodegradable and compostable. Other sustainable materials may be used. The interlocking of the cover with the cup by both interference fit and interlocking of the tabs and notches preferably excludes the need for other fastening devices to secure the cover and cup together. In one application the container is used to transport bait used in fishing but may be used for transporting food or non-food materials. When transported to outdoor natural environments, as in the case of fishing, the biodegradable feature of the container serves to preserve the environment in the event the container is not disposed of in an environmentally conscious manner as the container will degrade and not remain indefinitely intact in the environment as would plastic containers.

Containers formed of molded fiber manufactured materials typically include a cover formed of a same material as a cup. Such containers employ solely a limited friction fit due to a limited engagement area between the cup and cover to secure the two together during transport. However, containers of this type do a poor job of keeping the cover and cup together during rough handling occurring during shipping and stocking, and are also prone to separation due to dropping. Hence, additional means are required to secure the cover to the cup which complicate packaging and are typically not biodegradable. Thus, there exists a need for a container that is environmentally sound in that it is composed of biodegradable materials and also provides for secure engagement of the cover to the cup without additional plastic or other non-biodegradable sealing means

SUMMARY OF THE INVENTION

Briefly stated, the present invention provides a container that includes a container body which defines a volume wherein a product is to be held and a cover that engages the container body to provide sufficient sealing in conjunction with the container body for the product contained therein. The container body defines an opening to the volume and the opening defines a throat of the container. The cover is configured to act as a plug in the throat of the container which provides an interference fit. The cover has an outer flange which defines tabs and the container body has an outer flange which defines notches which are configured to mechanically interlock with the tabs when the tabs are bent to engage the notches and thereby secure the cover to the container.

An embodiment of the present invention provides s container for storing a product, the container having a base member formed to define and interior cavity in which the product is situated, the base member having a base member side wall defining a throat through which the product is introduced, the base member being formed as a molded fiber product having a rough side resultant from molding fibers on a screen, and a smooth side which is smoother than the rough side, and the rough side facing the interior cavity such that the throat presents the rough side in an inward direction. The container further includes a cover member formed as a molded fiber product having a rough side resultant from molding fibers on a screen, and a smooth side which is smoother than the rough side, the cover member having a cover member side wall and a cover interior portion from which the cover member side wall extends to define a concavity, the cover member side wall being dimensioned to create an interference fit in the throat of the base member when the cover member is press fit into the throat of the base member such that the cover member side wall presents the rough side of the cover member to the rough side presented by the throat of the base member. The container includes at least one tab extending from one of the cover member and the base member, the tab having a tab width at an exterior portion thereof, and the container also includes at least one notch defined by another one of the cover member and the base member, the at least one notch having a notch width at an interior portion thereof. The at least one tab and the at least one notch are situated such that when the cover member is press fit in the throat, the at least one tab is deflectable to be situated in the at least one notch and the at least one tab has a composition permitting the at least one tab to remain in an at least partially deflected state such that the tab width is situated to engage the notch width in the event the cover member moves in a direction to exit said throat. The tab width is greater than the notch width such that engagement of the tab width with the notch width prevents displacement of the cover member from the throat.

The present invention further includes a configuration wherein the base member includes a flange projecting radially outward from the side wall defining the throat, and the flange defines the at least one notch; and the cover member includes the at least one tab extending radially outward from the cover member prior to deflection of the a least one tab, and the deflection of the at least one tab engages said at least one tab with said at least one notch opening.

The container of the present invention described above further include the feature wherein the cover member side wall is inclined relative to a plane normal to an axis of the throat such that the cover member side wall tapers inward, and the base member side wall is inclined relative to the plane such that the throat tapers inward with further progression into the throat.

The above, and other objects, features and advantages of the present invention will become apparent from the following description read in conjunction with the accompanying drawings, in which like reference numerals designate the same elements.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings are as follows:

FIG. 1 is a bottom and side perspective view of a cup of a container of the present invention;

FIG. 2 is a top and side perspective view of a cover of the container of the present invention;

FIG. 3 is a top and side perspective view of portions of the cup and cover showing a tab and notch engagement;

FIG. 4 is a side elevation view of the cup of the present invention;

FIG. 5 is a top view of the cup of the present invention;

FIG. 6 is a side cross-sectional view of the cup of the present invention taken along line VI-VI of FIG. 5;

FIG. 7 is a top view of the cover of the present invention;

FIG. 8 is a side elevation view of the cover of the present invention;

FIG. 9 is a side cross-sectional view of the cover of the present invention taken along line IX-IX of FIG. 7;

FIG. 10 is a side cross-sectional view of portions of the cup and cover of the present invention engage with one another; and

FIG. 11 is a side elevation view of an alternative embodiment of the invention.

DETAILED DESCRIPTION

Referring to FIGS. 1 and 2, a preferred embodiment of the present invention comprises a cup 10 and a cover 12. The cup 10 and cover 12 are preferably formed of annually renewable, fully sustainable raw fiber materials as a molded fiber manufactured product. In the preferred embodiment the product is molded to provide a wall thickness T1 in a manner as discussed herein. Furthermore, the cup 10 is lined with a bio-resin made from poly lactic acid. The resultant material is biodegradable and compostable. While it is preferred that the material of the cup be that of sustainable raw fibers, unless specifically required by the appended claims, this is not to be considered limiting to the scope of the invention. Furthermore, the wall thickness T1 may be varied to suit the demands of the application.

The cup 10 is formed circular as shown in the plan view of FIG. 5 but is not limited to a circular configuration and may be configured oblong, rectangular, or in an arbitrary shape as the particular application may require. The cup 10 has a cup flange 14 which defines notches 16.

Referring to FIGS. 4 and 6, the cup flange 14 connects to a first inclined side wall 18 which is inclined at a first angle Al relative to a plane P1 of the cup flange 14. A step 20 connects the first inclined side wall 18 with a second inclined side wall 22 which defines a second angle A2 relative to the plane P1. The cup 10 has an overall cup height H1 and the first inclined side wall 18 has a wall height H2 including a thickness of the cup flange 14 defined by the material wall thickness T1 of the cup 10. The second inclined side wall 22 adjoins base curved wall 24 which in turn adjoins a cup bottom 26. The base curved wall 24 has a first radius R1 and the cup bottom 26 has a diameter D1. A curved portion adjoining the cup flange 14 to the first inclined side wall 18, and a curved portion adjoining the first inclined side wall 18 to the second inclined side wall 22 have an outer radius of R3. Dimples 28 are formed in the base curved wall 24 and serve as stiffening structures.

In the illustrated preferred embodiment of the cup 10, the first inclined side wall 18, the step 20, and the second inclined side wall 22 combine to form a cup side wall 30. However, the present invention is not limited to such a configuration. For example, the step portion 22 may be omitted and a continuous straight side wall substituted therefore. Furthermore, such a side wall need not be straight but may be curved.

Referring to FIG. 5, a plan view of the cup 10 is shown which illustrates placement of notches 16 at 120° intervals about the perimeter of the cup flange 14. The number of notches and their placement may be varied and such variations are considered to be within the scope of the present invention.

As shown in FIGS. 5 and 6, the cup flange 14 has an outer radius R4 and an inner radius R5. The first inclined side wall 18 forms a cup opening 32 at a top of the first inclined side wall 18 which has a radius R6 at a top of the cup 10 and which differs from the radius R5 by a radial dimension of a curved portion joining the cup flange 14 to the first inclined side wall 18. The cup opening 32 continues along the length of the first inclined side wall 18 to form a tapered throat 36 narrowing with further progression into the cup opening 32.

The notches 16 have opposing notch sides 40 which taper outward when progressing from the inner radius R5 to the outer radius R4. In other words, an inner circumferential length D2 of the notches 16 is less than an outer circumferential length D3 of the notches 16 such that the notches 16 have a flared configuration the function of which is discussed below. In the preferred embodiment the opposing notch sides 40, at their innermost and outermost positions define linear distances D2 and D3 such that D3>D2.

Referring to FIGS. 2 and 7-9, the cover 12 has a cover flange 50, an inclined cover side wall 52, and a cover interior portion 54. The cover interior portion 54 optionally includes an annular portion 56, an inclined step portion 57, and a central portion 58. Alternatively, the cover interior portion 54 may be formed as a flat disc or include further steps and annular portions. At the joining of the cover interior portion 54 and the inclined cover side wall 52 is a rounded corner having a corner radius R2 which provides for ease of alignment for insertion of the cover 12 into the cup 10. The cover interior portion 54 has a diameter D4. As shown in FIG. 8, the cover 12 has a cover height H3. The height H3 of the cover 12 is selected such that the inclined cover side wall 52 has sufficient surface area to function as a plug when the cover 12 is inserted into the opening of the cup 10 and firmly engage the first inclined side wall 18 as is explained below. In the preferred embodiment the height H3 is approximately 0.40 inches. However, sufficient engagement may be achieved with H3 being at least greater than 0.25 inches. It will be further realized that, dependent upon coefficients of friction of the first inclined side wall 18 and the inclined cover side wall 52, H3 may be set lower.

Referring to FIGS. 7 and 9, the cover flange 50 has an outer radius R7 and an inner radius R8. The inclination angle of the inclined cover side wall 52 is preferably set to match the angle A1 of the first inclined side wall 18 such that when the cover 12 is press fit into the opening defined by the first inclined side wall 18 of the cup 10, i.e., the tapered throat 36, the inclined cover side wall 52 securely engages the first inclined side wall 18 of the cup as shown in FIG. 10 by means of an interference fit of an interference dimension F1 taken normal to the inclined cover side wall 52 and the first inclined side wall 18. However, the inclination angle of the inclined cover side wall 52 need not match the angle A1 but may instead be slightly greater provided that the proper interference fit results. Such a variation is considered to be within the scope and spirit of the present invention.

The interference fit is configured to require an insertion pressure of approximately 14 to 20 pounds total applied to the overall top cover for the disclosed preferred embodiment in order to position the cover 12 and cup 10 securely together as shown in FIG. 10. This insertion pressure may be varied by altering the interference dimension F1, or the coefficients of friction of the engaging surfaces of the cup 10 and cover 12 as is further discussed below. Furthermore, the insertion pressure will vary dependent upon the sizes of the cup and cover 12 and the resultant surface area of the engaging surfaces. The interference fit serves to provide sealing effective to prevent liquids from readily leaking from the engaged cup 10 and cover 12. However, it will be appreciated that such sealing may not be required for non-liquid products held in the container of the present invention and thus the interference fit may be adjusted to a suitable level for the product involved.

While the interference fit is sufficient in many instances to secure the cover 12 in the throat 36 of the cup 10, handling of the container during shipping may jar the cover 12 loose despite the interference fit. As the cup 10 and cover 12 are both formed of biodegradable fiber material, it is desirable that the cover be securely fastened without addition of clips or shrink sleeving which would not be biodegradable and would complicate assembly. Nevertheless, unless so stated in the appended claims, additional fastening mechanisms are not considered excluded from the scope and spirit of the present invention. However, the preferred embodiment excludes such additional mechanisms.

Referring to FIG. 7, to achieve the result of secure cover fastening, the cover 12 is provided with tabs 60 which are bent over once the cover 12 is situated in the cup 10 in the manner as shown in FIG. 3. The tabs 60 are defined by cover flange notches 64 so as to have opposing tab sides 62 which are tapered inward towards each other commensurate with inward progression into the cover flange 50. Thus, at the innermost portion of the tabs 60, an inner tab width D5 is less than an outer tab width D6 at the widest portion of the tab 60. The inner and outer tab widths D5 and D6 are selected such that the tabs 60, when bent, may pass through notches 16 with sufficient clearance, or minimal interference, that the angled ends, or ears 66, of the tabs 60 remain physically intact to perform a locking function by interlocking with the tapered configuration of the notches 16. The material of the cover 12 is of a composition which allows the tabs 60 to remain bent in a position whereat the ears 66 are disposed below narrow inner ends of the notches 16. The outer tab width D6 is selected to be greater than the inner notch width D2 to perform an interference locking function. Preferably, the inner tab width D5 is selected to be greater than the inner notch width D2 so that, when the tabs 60 are bent downward to within the range of 30 degrees to 120 degrees, however preferably approximately 90 degrees relative to the plane P1 of the cup flange 14, tab sides 62 of the ears 66 of the tabs 60 are deformed at locations 70, shown in FIG. 3, to accept the opposing notch sides 40 thereby forming an interference fit that locks the cover 12 onto the cup 10. As a result of the interference fit of the tabs 60 into the notches 16, and deformation of the tab sides 62, the cover 12 is secured by the additional locking feature of the tabs 60 and notches 16 so that dependence of securing the cover 12 to the cup 10 is not solely reliant on the interference fit of inclined cover side wall 52 with the first inclined side wall 18 of the cup 10 which form the throat 36. Thus, the combination of two interference fits provides for secure disposition of the cover 12 in the cup 10 such that jarring during handling of the container will not dislodge the cover 12 from the cup 10. It will be realized that deformation of the opposing notch side walls 40 may also be substituted for the deformation of the tab sides 62 or effected in combination with the deformation of the tab sides 62 and that such embodiments are within the scope and spirit of the present invention. Additionally, configurations resulting in absence of deformation may also be effected provided that the tab side 62 firmly engage bottom edges of the opposing notch sides 40 when the tabs 60 are bent downward.

The scope and spirit of the present invention is further considered to include configurations wherein the positioning of tabs and notches is reversed such that the notches 16 are defined in the cover flange 50 and the tabs 60 are defined in the cup flange 14. Still further, the scope and spirit of the present invention is intended to include a combination of notches and tabs formed in both the cup flange 14 and the cover flange 50 in a manner that is engageable to secure the cover 12 to the cup 10. However, it is considered preferable that the tabs 60 be limited to the cover flange 50 and the notches 16 be limited to the cup flange 14 as this allows the tabs 60 to be deflected downward into a volume defined by a downward projection of a circle circumscribing the cover flange 50 and thus does not require additional packing space to be allocated to upward projecting tabs above the plane of the cover flange 50.

In the preferred embodiment of the cup 10, the values of the above noted dimensions are about the values listed in Table I below.

TABLE I DIMENSION VALUE T1 0.067 INCHES H1  2.98 INCHES H2  0.50 INCHES H3  0.40 INCHES D1  2.59 INCHES D2  0.56 INCHES D3  0.73 INCHES D4  4.23 INCHES D5  0.61 INCHES D6 0.725 INCHES R1 0.315 INCHES R2 0.079 INCHES R3 0.047 INCHES R4  2.54 INCHES R5  2.31 INCHES R6  2.22 INCHES R7  2.56 INCHES R8  2.30 INCHES A1 98.50 DEGREES A2   202 DEGREES F1  .007 INCHES The present invention is not limited to the above noted dimensions which are presented merely for illustrating a presently preferred embodiment and may be altered to accommodate the application at hand. The dimensions presented are considered approximate allowing for about a +/−10% deviation. A further embodiment of the invention includes a wall thickness of 0.039″+/−10% and the height H1 is about 2.0″+/−10% . In this further embodiment the angles recited above remain approximately the same and the diameter of the base is proportionally increased.

The cup 10 and cover 13 are formed by molding a slurry of the raw fiber materials on molds formed of a screen mesh which allow the moisture content of the slurry to escape. Sides of the cup 10 and cover 13 that are formed contacting the screen mesh are left with an impression of the screen mesh which forms a rough surface in comparison with the opposing side which is formed smooth relative to the rough side. In the preferred embodiment the rough side is formed using a screen mesh having a wire pitch of approximately 33/inch. Varying mesh dimensions may be used to practice the invention but preferably the pitches are in the range of 20/inch to 60/inch. When the slurry has dried, the molded product is removed and placed in a die which is heated and the final edges are then cut. Articles made from such molded fibers are commonly known as a molded fiber manufactured product and further explanation of the process is omitted as such processing is within the knowledge of those skilled in the art.

In the preferred embodiment of the present invention the rough side is provided on the inside of the cup 10 which is not the standard practice in the industry. In combination with the cup 10, the cover 12 has the rough side provided on the inside surface of the cover 12. When the rough surface of the cover 12 engages the rough surface of the cup 10, sufficient friction exists to provide a secure engagement preventing leakage of product sealed in the container of the present invention. If less engagement force is required, the cover 12 may be molded to provide the smooth surface on the inside surface of the cover 12 such that the smooth surface of the cover 12 engages the rough surface of the cup 10. Alternatively, the cup 10 may be formed with the rough surface on the outside and the cover 12 formed with the rough surface on the outside. For the purpose of this disclosure, the inside surface is considered to be a surface facing an interior volume of the cup 12 wherein a product is held when the cover 12 and cup 10 are engaged and an outside surface is a corresponding opposite side of the molded product which is exposed to the exterior environment.

The raw fiber material used in the slurry includes a combination of sustainable, annually renewable raw materials such as sugarcane bagasse, bamboo, wheat straw, rice straw and bull rush fibers in various combination and ratios or as standalone components. In the preferred embodiment, the fiber material used is bagasse which is a pulp-like residual by-product of sugar cane production and is annually renewable. However, the scope and spirit of the present invention includes using other fiber products, such as bamboo, wheat straw, rice straw, and bull rush fibers or combinations thereof.

Once the cup 10 and cover 12 are molded, they are lined with poly lactic acid on the inside surfaces facing the product to be contained to form a long term moisture barrier, enhance shelf life of a product contained therein, and to provide a higher coefficient of friction between the cup and lid.

In summary, the height H3 of the cover 12 is selected such that the inclined cover side wall 52 has sufficient surface area to function as a plug when the cover 12 is inserted into the opening of the cup 10 and firmly engage throat 36 formed of the first inclined side wall 18. The interference fit of the tabs 60 into the notches 16, and deformation of the tab sides 62, secures the cover 12 by the additional locking feature of the tabs 60 and notches 16 so that dependence of securing the cover 12 to the cup 10 is not solely reliant on the interference fit of inclined cover side wall 52 with the first inclined side wall 18 of the cup 10 which form the throat 36.

Referring to FIG. 11, an alternative embodiment of the present invention provides a cup 10′ and a cover 12′ that are formed interconnected by a hinge element 80 formed of the same material as the cup 10′ and cover 12′ and configured to permit the rotation of the cover 12′ into the cup 10′. such hinge elements are known and typically formed by providing an indentation along which the folding occurs. The cup 10′ and the cover 12 are the same as cup 10 and cover 12′ with the exception that they are formed joined by the hinge element 80 and may be configured to have a single tab and notch interlock, here shown by the notch 16 on the opposing side of the cup flange 14 from the hinge element 80 and the tab 60 on the opposing side of the cover flange 50 from the hinge element 80. When the cover 12′ is folded over into the throat of the cup 10′, an interference fit of the cover 12′ into the throat is established and the tab 60 is engaged into the notch 16. As the tab and notch configuration are the same as described above with regard to the first embodiment, further description is omitted except that a single tab and notch combination may be used. However, more than one tab and notch combination may also be employed in the embodiment of FIG. 11.

Having described preferred embodiments of the invention with reference to the accompanying drawings, it is to be understood that the invention is not limited to those precise embodiments, and that various changes and modifications may be effected therein by one skilled in the art without departing from the scope or spirit of the invention as defined in the appended claims. The present invention is considered to include all functional combinations of the above described features and is not limited to the particular structural embodiments shown in the figures as examples. The scope and spirit of the present invention is considered to include modifications as may be made by those skilled in the art having the benefit of the present disclosure which substitute, for elements presented in the disclosure, structures upon which the claim language reads or which are equivalent thereto, and which produce substantially the same results associated with those corresponding examples identified in this disclosure for purposes of the operation of this invention. Additionally, the scope and spirit of the present invention is intended to be defined by the scope of the claim language itself and equivalents thereto without incorporation of structural or functional limitations discussed in the specification which are not referred to in the claim language itself. Furthermore, claim elements introduced in the singular tense are intended to read on pluralities unless specifically limited in the claim language. 

1. A container for storing a product, comprising: a base member formed to define and interior cavity in which the product is situated, the base member having a base member side wall defining a throat through which the product is introduced, the base member being formed as a molded fiber product having a rough side resultant from molding fibers on a screen, and a smooth side which is smoother than the rough side, and the rough side facing the interior cavity such that the throat presents the rough side in an inward direction; a cover member formed as a molded fiber product having a rough side resultant from molding fibers on a screen, and a smooth side which is smoother than the rough side, the cover member having a cover member side wall and a cover interior portion from which the cover member side wall extends to define a concavity, the cover member side wall being dimensioned to create an interference fit in the throat of the base member when the cover member is press fit into the throat of the base member such that the cover member side wall presents the rough side of the cover member to the rough side presented by the throat of the base member; at least one tab extending from one of the cover member and the base member, said tab having a tab width at an exterior portion thereof; at least one notch defined by another one of the cover member and the base member, said at least one notch having a notch width at an interior portion thereof; said at least one tab and said at least one notch being situated such that when the cover member is press fit in the throat, the at least one tab is deflectable to be situated in said at least one notch and the at least one tab has a composition permitting the at least one tab to remain in an at least partially deflected state such that said tab width is situated to engage said notch width in the event the cover member moves in a direction to exit said throat; and said tab width being greater than said notch width such that engagement of said tab width with said notch width prevents displacement of said cover member from said throat.
 2. The container of claim 1, wherein: the base member includes a flange projecting radially outward from the side wall defining the throat, and the flange defines said at least one notch; and the cover member includes said at least one tab extending radially outward from the cover member prior to deflection of said at least one tab, and said deflection of said at least one tab engages said at least one tab with said at least one notch opening.
 3. The container of claim 2, wherein: said cover member side wall is inclined relative to a plane normal to an axis of the throat such that said cover member side wall tapers inward; and said base member side wall is inclined relative to said plane such that said throat tapers inward with further progression into said throat. 